Apparatus for spin-forming a circular body from a flat blank metal workpiece

ABSTRACT

A machine for spin-forming a solid disk blank having a center axial bore into a pulley configuration exhibiting an outer peripheral pulley groove and a flanged bore bearing retainer. Die members maintain the disk blank on the machine axes by clamping the disk blank between an upper and lower die members. A power source affects rotational motion of at least one of the die members to affect rotation of the disk blank. A splitting tool, a swaging tool, and a splitting-swaging tool are moveable for engaging the disk blank and affecting splitting and swaging of the bore and peripheral edge. A rotatable inner tool spindle comprises the splitting-swaging tool connected thereto and is movable horizontally such that the tool splits and swages the center axial bore. A power source affects rotational motion of the spindle and thus the rotational motion of the splitting-swaging tool.

TECHNICAL FIELD

This invention generally pertains to machine operations for forming a one-piece pulley or like-type body from a solid circular metal blank of material.

BACKGROUND

In the art of metal fabrication, there are methods for creating pulleys, sheaves, and like-type bodies from a solid circular metal blank by splitting the exposed edges of the blank. For example, a machine can split and swage an outer peripheral edge of a solid disk blank to form a pulley groove and also split and swage an inner bore edge to form upper and lower flanges for retaining a bearing.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings incorporated herein and forming a part of the specification illustrate the example embodiments.

FIG. 1A is an elevational view, in cross-section, of a solid metal circular disk blank as may be applied to the formation of a pulley or like-type body in the machine of the present invention;

FIG. 1B is an elevational view, in cross-section, of the disk blank shown in FIG. 1A illustrating a splitting operation which affects forming of the disk blank into a pulley body;

FIG. 1C is an elevational view, in cross-section, of a production pulley as made by a metal splitting and swaging machine operation;

FIG. 2 is an elevational view, in partial cross-section and partially schematic, illustrating machine operations as may be accomplished by the present invention;

FIG. 3 is an elevational view, in partial cross-section and partially schematic, illustrating a configuration of the machine;

FIG. 4 is an elevational view, in partial cross-section and partially schematic, illustrating an alternate configuration of the machine;

FIG. 5 is an enlarged elevational view, in partial cross-section, illustrating a cutting and swaging mechanism which forms a primary portion of the machine comprising this invention;

FIG. 6 is an elevational view, in cross-section, of a portion of the machine shown in FIG. 3 illustrating an alternative clamping configuration of the circular disk blank as may be applied to this invention.

OVERVIEW OF EXAMPLE EMBODIMENTS

The following presents a simplified overview of the example embodiments in order to provide a basic understanding of some aspects of the example embodiments. This overview is not an extensive overview of the example embodiments. It is intended to neither identify key or critical elements of the example embodiments nor delineate the scope of the appended claims. Its sole purpose is to present some concepts of the example embodiments in a simplified form as a prelude to the more detailed description that is presented later.

In accordance with an example embodiment, there is disclosed herein a machine a machine for forming a bore in a disk blank. The machine comprises a first motor coupled with the disk blank which causes the disk blank to rotate. The machine further comprises a second machine coupled with a tool for forming the bore in the disk blank.

In accordance with an example embodiment disclosed herein, there is described a machine for forming a bore in a disk blank. The machine comprises a first motor coupled with the disk blank which causes the disk blank to rotate. The machine further comprises a second motor coupled with a tool for forming the bore in the disk blank. The tool may suitably comprise a splitting tool, a swaging tool, or both a splitting tool and a swaging tool, and a lateral motion inducing mechanism or motor for moving the internal tool spindle horizontally a specified distance such that the tool engages the disk blank center axial bore.

DETAILED DESCRIPTION OF EXAMPLE EMBODIMENTS

This description provides examples not intended to limit the scope of the appended claims. The figures generally indicate the features of the examples, where it is understood and appreciated that like reference numerals are used to refer to like elements. Reference in the specification to “one embodiment” or “an embodiment” or “an example embodiment” means that a particular feature, structure, or characteristic described is included in at least one embodiment described herein and does not imply that the feature, structure, or characteristic is present in all embodiments described herein.

With reference to the drawings, FIGS. 1A, 1B, and 1C illustrate a method of converting a solid metal circular disk blank into a formed operational body such as, for example, a pulley as may be driven into rotation by a belt in any known mechanical drive operation. In FIG. 1A, a disk blank is shown and generally indicated by reference numeral 10 and it is characterized by a thickness dimension “t” and an overall diameter dimension “D”. The thickness “t” and diameter “D” are predetermined specifications which are necessary such that the requirements imposed on a final product configuration and its application will be met and this will be apparent as this description proceeds.

The disk blank 10 may have a center axial bore 12 having a bore edge 12 a and further includes at least two positioning bores 14, the purpose of which will be described hereinafter. In FIG. 1B, the disk blank 10 is shown where edge splitting has been initiated wherein the outer peripheral edge 16 is split into two halves each exhibiting a thickness dimension “t/2”. However, in other embodiments the splitting can occur at a point on the peripheral edge that does not result in two halves that are equal thickness.

In a like manner, the bore edge 12 a is split into two halves each exhibiting a thickness dimension “t/2”. However, in other embodiments the splitting can occur at a point on the bore edge 12 a that does not result in two halves that are equal thickness. A continued splitting and eventual swaging of the outer peripheral edge 16 and bore edge 12 a results in a pulley product as shown in FIG. 1C. Thus, the disk blank 10 is converted into a body characterized by a pulley groove indicated at reference numeral 18 and a center axial bore 12 formed into bearing retaining flanges 20 which may be configured to contain a bearing as indicated by ghost lines at reference numeral 22.

Referring now to FIG. 2 of the drawings, a machine operation in accordance with example embodiment of the present invention for forming a pulley body as shown in FIG. 1C is illustrated and generally indicated by reference numeral 31. The figure is a partial elevational view and is partially schematic for the purpose of illustrating the positioning and operational steps which are necessary in a machine operation to form the pulley body of FIG. 1C. In the figure, a disk blank 10 similar to that shown in FIG. 1A is mounted between an upper die member 32 and a lower die member 34 and is axially positioned on a vertical machine axis indicated by line Ay-Ay in the figure. Positioning bores 14 in the disk blank 10 are matched with at least a pair of positioning die studs 36 in the lower die member 34. The die members 32,34 and the disk blank 10 are all, therefore, rotatable about the machine Ay axis. In a position exterior of the die members 32,34 is a splitting tool 43 which is movable along the Bx horizontal axis and is rotatable about a parallel Aya vertical axis. The splitting tool 43 moves along the Bx axis such that it makes engagement with the outer peripheral edge 16 of the disk blank 10 to affect splitting of the outer peripheral edge 16 into two halves of thickness dimension “t/2” as shown in FIG. 1B of the drawings. Also in a position exterior of the die members 32,34 is a swaging tool 42 which is movable along the Bx horizontal axis and is rotatable about a parallel Ayb vertical axis. From this description it can be appreciated that the tools 42 and 43 are instrumental in splitting and forming of the pulley groove 18 as illustrated in FIG. 1C.

Continuing with reference to FIG. 2, a third tool 44 for splitting and swaging is positioned within the center axial bore 12 via a vertical motion along the Ay machine axis. The tool 44 is characterized by a splitting edge 46 which moves along the Bx horizontal axis to engage the disk blank center axial bore edge 12 a and affect splitting of the bore edge into two halves each exhibiting a thickness dimension “t/2”. The tool 44 is also characterized by a shape which affects swaging of the upper half portion vertically upwardly while also affecting swaging of the lower half portion vertically downwardly to thus form bearing retaining flanges 20 as shown in FIG. 1C. In this respect, it should be pointed out that the machine of this invention is capable of forming both upwardly and downwardly oriented bearing retaining flanges 20 simultaneously in a single machine operation. This will be made apparent as the description proceeds. In addition, it will be apparent that the pulley groove 18 may exhibit many and various configurations and this is dependent upon the shape of the swaging tool being applied to the outer peripheral edge 16.

Referring to FIG. 3 of the drawings, a machine according to an example embodiment is illustrated schematically and generally indicated by reference numeral 100. The machine 100 is characterized by an upper die member 130 and a lower die member 120 which are mounted for rotational motion about a vertical Ay machine axis as shown. The upper die member 130 is an annular-shaped piece with a center axial cone-shaped bore further including a lower end 130 a which is adapted for engagement with a disk blank 10 and an upper end 130 b which is adapted for mounting to an upper die spindle 135. In an exemplary embodiment, the upper die member 130 may also be conically-shaped or any other suitable shape for engagement with a disk blank. A splitting-swaging tool 155 attached to the end of an internal tool spindle 150 passes through the bore in the upper die member 130 for affecting splitting and swaging of the disk blank 10. The center axial bore of the upper die member 130 may also be any other suitable shape which allows for a splitting-swaging tool 155 to engage the disk blank 10. In a position exterior of the die members 32,34 is a splitting tool 43 which is movable along the Bx horizontal axis and is rotatable about a parallel Ayc vertical axis. The splitting tool 43 moves along the Bx axis such that it makes engagement with the outer peripheral edge 16 of the disk blank 10 to affect splitting of the outer peripheral edge 16 into two halves of thickness dimension “t/2” as shown in FIG. 1B of the drawings. Also in a position exterior of the die members 32,34 is a swaging tool 42 which is movable along the Bx horizontal axis and is rotatable about a parallel Ayb vertical axis. From this description it can be appreciated that the tools 42 and 43 are instrumental in splitting and forming of the pulley groove 18. Continuing with FIG. 3, the upper die spindle 135 is operatively connected via bearings 45 to a pair of stationary column-connecting assemblies 60 which connect at least two top columns 40 with at least two bottom columns 30. The bottom columns 30 are operatively connected to the mounting base support member 110 via bottom column adapters 119. The base support member 110 is operatively connected to the base frame 111 which supports and provides stability to the spin-forming machine 100. In an exemplary embodiment, the stationary column assemblies 60 comprise at least a bottom column adapter 50 and a bearing housing 55, which may comprise a top bearing retainer 55 a and a bottom bearing retainer 55 b or may consist of a singular housing, which are connected to the columns 30,40 and each other by various connecting means, such as bolts, screws, or other various forms of connection. Bearings 45 located between the upper die spindle 135 and the stationary bearing housing 55 allow for the rotational motion of the upper die spindle 135 about the vertical Ay machine axis. The bottom bearing retainer 55 b located adjacent to the upper die spindle 135 and top bearing retainer 55 a help provide support for the bearings 45 which rotatably support the upper die spindle 135.

Continuing with FIG. 3, the lower die member 120 is carried by a lower die spindle 125 which allows for rotational motion of the lower die member 120 about the machine Ay axis. The lower die member 120, which is annular in shape, may be characterized by at least a pair of positioning studs 122 configured for matching engagement within the positioning bores 14 in the disk blank 10 such that the disk blank 10 is both vertically and horizontally located with reference to the machine Ay axis and the horizontal Bx axis. Other techniques for locating the disk blank 10 may be used and these will be illustrated and discussed hereinafter. In any case, the studs 122 extend to engage the upper die member 130 via matching bores 132. The lower die spindle 125 is operatively connected to and supported by a ring member or lower spindle housing 128 via bearings 45. The lower spindle housing 128 is operatively connected to the bottom columns 30 via a column holder assembly 70. The column holder assembly 70 is in slidable engagement with the bottom columns 30. In an exemplary embodiment, the column holder assembly 70 is operatively connected to a spindle support plate 72 for supporting the lower spindle housing 128. In an exemplary embodiment not shown, the column holder assembly 70 moves on a track secured to, or that are a part of, the bottom columns 30.

Continuing with FIG. 3, a first drive motor 84 is provided for causing rotational motion of the lower die spindle 125 upon which the lower die member 120 is operatively connected. The first drive motor 84 is preferably electrically powered but may also be powered by other means, such as by combustion. Because during operation of the machine 100 the upper die member 130 and the lower die member 120 are interconnected thru two or more positioning studs 122 which are carried by the lower die member 120, both die members 120,130 are driven into rotation by the first drive motor 84. The disk blank 10 is therefore also driven into rotational motion about the Ay machine axis by this arrangement. The first drive motor 84 is operatively connected to the lower spindle housing 128 via a lower motor support 118 such that its output shaft 82 is rotatable about the machine Ay axis. The drive motor output shaft 82 is operatively connected to the lower die spindle 125 via a coupling hub 80 comprising suitable coupling devices. The lower motor support 118 is operatively connected to the lower spindle housing 128 such neither experience rotation about the machine Ay axis while the first drive motor 84 is in operation.

In another exemplary embodiment not shown in the figures, the first drive motor 84 is positioned off of the Ay machine axis and drives the rotation of both die members 120,130 via a spur-ring gear combination. Using this method for causing rotational movement of the die members 120,130 allows for a more spacious area beneath the lower die member 120 or above the upper die member 130, which could be used for housing other various components. For this configuration see, for example, U.S. Pat. No. 5,979,203 to Radocaj, incorporated by reference herein in its entirety.

As shown in FIG. 3, the first drive motor 84 is enclosed on at least two sides by cylinder rod supports 116 which are operatively connected by a cylinder rod adapter 114 for supporting forces from a lower lifting mechanism 90. The lower lifting mechanism 90 can adjust the vertical height of the lower die member 120 with a lower lifting mechanism output shaft 92. In an exemplary embodiment, the cylinder rod supports 116 may also be an enclosure formed from a single piece of material that the cylinder rod adapter 114 may be connected thereto. The lifting mechanism 90 is positioned along the vertical Ay axis and operatively connected to a mounting base support member 110. The lower lifting mechanism output shaft 92 is positioned along the vertical Ay axis and operatively connected to the cylinder rod adapter 114. In an exemplary embodiment not shown, the lower lifting mechanism 90 may be positioned away from the vertical Ay axis and therefore so may the output shaft 92. The lifting mechanism output shaft 92 may be continuously connected to the cylinder rod adapter 119 or can be disengaged during use or after use of the machine 100.

Continuing with FIG. 3, mounted axially within the upper die member 130 is a splitting-swaging tool 155 which is operatively connected to a rotatable, vertically and laterally-movable internal tool spindle 150. The spindle 150 is operatively connected to a ring member or tool spindle housing 156 via bearings 45 that allow the spindle 150 to be rotatable about the machine Ay axis when at the starting position and continuously rotatable during operation of the machine during lateral movement of the spindle 150 from the machine Ay axis to the parallel Ayc axis (as shown in FIG. 5). The tool spindle housing 156 is operatively connected to the top columns 40 via column holder assemblies 70 analogous to the column holder assemblies 70 in slideable engagement with the bottom columns 30. The column holder assemblies 70 are in slidable engagement with the top columns 40 and are operatively connected to spindle assembly plate adapters 74 and lateral spindle slides 76 which allow for lateral/horizontal movement of the internal tool spindle 150.

The internal tool spindle 150, along with the splitting-swaging tool 155, are moveable from the machine Ay axis to a parallel Ayc axis by a lateral motion inducing mechanism, such as an electric cylinder, hydraulic cylinder, pneumatic cylinder, motor, or any other suitable powered mechanism that can induce lateral motion, and such mechanism is generally indicated at reference numeral 98. In an exemplary embodiment, the lateral motion inducing mechanism 98 is located on the side of the machine but it can be placed anywhere on or near the machine, including the front, back, top, or bottom. The motion of the splitting-swaging tool 155 from the Ay axis to the Ayc axis affects splitting and swaging of the disk blank center axial bore 12 as illustrated in FIGS. 1 B and 1C.

A hydraulic motor support 148 is operatively connected to the tool spindle housing 156 and supports a second drive motor 88, which is operatively connected thereto. The second drive motor 88 affects rotational movement of the internal tool spindle 150 about the machine Ay axis. This rotational motion of the tool spindle 150 can be initiated before the splitting-swaging process and continue throughout the splitting-swaging process of the inner bore until the splitting-swaging tool 155 reaches the Ayc axis or even until the splitting-swaging tool 155 returns to the machine Ay axis after the splitting-swaging process. A controller 200 controls the rotational speeds of the first and second drive motors 84, 88. In an example embodiment, the controller 200 controls the speeds of the first and second driver motors 84, 88 so that the rotational speed of the splitting-swaging tool 155, is equal to the rotational speed of the disk blank 10 during the splitting-swaging process, so that there is no rotational motion between the splitting-swaging tool 155 and the disk blank 10. However, as those skilled in the art can readily appreciate, achieving identical matching speeds can be difficult in the physical world. Therefore, in an example embodiment, the rotational speeds of the first and second motors 84, 88 may be controlled to cause the rotational speeds of the disk blank 10 and the splitting-swaging tool 155 to be substantially equal to one another which as used herein is defined as the rotational speed of the splitting-swaging tool 155 is within 5% of the rotational speed of the disk blank 10. As those skilled in the art can readily appreciate, because the mechanical coupling between the first motor and the upper die spindle 135 may be different than the mechanical coupling between the second motor and the internal tool spindle 150 (e.g., direct drive vs. spur-ring gear combination), the rotational speeds of the motors 84, 88 may be different in order to achieve the appropriate rotational speeds of the splitting-swaging tool 155 and the disk blank 10.

Without the rotational motion of the spindle 150 during the splitting-swaging process, the splitting-swaging tool 155 may have a shorter lifespan compared to when the spindle 150 exhibits rotational motion. This can be attributed to the torsional shearing forces applied to the splitting edge 152 of the splitting-swaging tool 155 when the tool is initially at rest and comes into contact with the disk blank 10. In that case, when the rotational motion of the disk blank 10 contacts the splitting-swaging tool 155, the spindle 150, along with the splitting-swaging tool 155, begin to rotate as well. However, because the splitting-swaging tool 155 is starting from a rested position, there are torsional-friction losses associated with this configuration. These frictional losses are what affect tooling life. The greater the torsional-friction associated with a design, the more frequent the splitting-swaging tool 155 will have to be replaced. Therefore, by applying rotational power to the spindle 150 via the second drive motor 88 to affect rotational motion to the tool spindle 150 and splitting-swaging tool 155 before contact with the disk blank 10, there is a decrease in the torsional-friction forces applied to the tool 155 and thus the life of the tool 155 is increased. For example, the applicant has observed in one example embodiment that the life of the tool was incrased from 3,000 pieces to 15,000 pieces.

This same idea regarding decreasing torsional-friction forces upon the tool 155 can be applied to the splitting tool 43 and the swaging tool 41 (as illustrated in FIG. 2) which both make contact with the outer peripheral edge 16 of the disk blank 10. When the rotational speed of the spindle 150, and thus the splitting-swaging tool 155, approaches the rotational speed of the disk blank 10, the torsional friction forces applied to the splitting-swaging tool 155 are minimized. The greater the difference between the rotational speed of the spindle 150 and that of the disk blank 10, the greater the torsional-friction forces applied to the splitting-swaging tool 155. Thus, in an exemplary embodiment, the rotational speeds of the splitting-swaging tool 155, the splitting tool 43, and swaging tool 41 are substantially equal to the rotational speed of the disk blank 10 when the splitting-swaging process begins.

The second drive motor 88 has an output shaft 86 that is operatively connected to the tool spindle 150 via a coupling hub 80, or other suitable coupling devices, which is located in the interior of the hydraulic motor support 148. The second drive motor 88 is enclosed on at least two sides by cylinder rod supports 146 which are operatively connected by a cylinder rod adapter 144 for supporting forces from an upper lifting mechanism 94 that can adjust the vertical height of the tool spindle 150 and splitting-swaging tool 155 with an upper lifting mechanism output shaft 92. The lifting mechanism 94 is positioned along the vertical Ay axis and operatively connected to a top cylinder support member 112 and top frame member 113, which are operatively connected to the top columns 40. In an exemplary embodiment, the top cylinder support member 112 is operatively connected to the top frame member 113 which may comprise a box-like frame connecting the top columns 40. The top frame member 113 may be operatively connected to the top of the top columns 40 (shown in FIG. 3) or relatively close to the top of the top columns 40 allowing for the top of the lifting mechanism 94 to be flush with the top of the top cylinder support member 112 (not shown).

In an exemplary embodiment as show in FIG. 3, the lifting mechanism output shaft 96 is positioned along the vertical Ay axis and operatively connected to the cylinder rod adapter 144. In another exemplary embodiment not shown, the lifting mechanism 94 may also be positioned away from the vertical Ay axis. The lifting mechanism output shaft 96 is continuously connected to the cylinder rod adapter 144 so as to maintain a constant height of the spindle 150 and splitting-swaging tool 155 during operation of the machine 100. The lifting mechanism 94 may also be operated during the splitting-swaging process in order to affect different pulley shapes by raising and lowering the splitting-swaging tool 155.

Referring now to FIG. 4 of the drawings, an alternative embodiment is disclosed showing a similar but alternate design of the machine 100 as disclosed in FIG. 3. In this embodiment, machine 100 is designed with the splitting-swaging tool 155 located towards the bottom of the machine 100 rather than at the top. The machine 100 is characterized by an upper die member 130 and a lower die member 120 and these are mounted for rotational motion about a vertical Ay machine axis as shown. The lower die member 120 is an annular-shaped piece with a center axial cone-shaped bore having an upper end 120 a which is adapted for engagement with a disk blank 10 and a lower end 120 b which is adapted for mounting to a lower die spindle 125. In an exemplary embodiment, the upper die member 130 may also be conically-shaped or any other suitable shape for engagement with a disk blank. A splitting-swaging tool 155 attached to the end of an internal tool spindle 150 passes through the bore in the lower die member 120 for affecting splitting and swaging of the disk blank 10. The center axial bore of the lower die member 130 may also be any other suitable shape which allows for a splitting-swaging tool 155 to engage the center axial bore of the disk blank 10.

Continuing with FIG. 4, the lower die spindle 125 is operatively connected via bearings 45 to stationary column-connecting assemblies 60 which connect the top columns 40 with the bottom columns 30. The bottom columns 30 are operatively connected to the mounting base support member 110 via bottom column adapters 119. The base support member 110 is operatively connected to the base frame 111 which supports and provides stability to the machine 100. In an exemplary embodiment, the stationary column assemblies 60 comprise at least a bottom column adapter 50 and a bearing housing 55, which may comprise a top bearing retainer 55 a and a bottom bearing retainer 55 b or may consist of a singular housing, which are connected to the columns 30,40 and each other by various connecting means, such as bolts, screws, or other various forms of connection. Bearings 45 located between the lower die spindle 125 and the stationary column assemblies 60 allow for the rotational motion of the lower die spindle 125 about the vertical Ay machine axis. The bottom bearing retainer 55 b located adjacent to the lower die spindle 125 and top bearing retainer 55 a help provide support for the bearings 45 which rotatably support the lower die spindle 125.

Continuing with FIG. 4, the upper die member 130 is carried by an upper die spindle 135 which allows for rotational motion of the lower die member 120 about the machine Ay axis. The upper die member 130, which in a preferred embodiment is annular in shape, may be characterized by at least a pair of positioning studs 122 adapted for matching engagement within the bores 14 in the disk blank 10 such that the disk blank 10 is both vertically and horizontally located with reference to the machine Ay axis and the horizontal Bx axis. In a further embodiment not shown, the lower die member 120 may be characterized by at least a pair of positioning studs 122 adapted for matching engagement within the bores 14 in the disk blank 10 for aligning the disk blank 10 with the upper die member 130. Other techniques for locating the disk blank 10 can be found in U.S. Pat. No. 5,979,203 to Radocaj, incorporated herein by reference in its entirety. In any case, as shown in FIG. 4, the studs 122 extend to engage a lower die member 120 via matching bores 132. The upper die spindle 135 is operatively connected to and supported by a ring member 128 via bearings 45. The ring member 128 is operatively connected to the top column 40 via a column holder assembly 70. The column holder assembly 70 is in slidable engagement with the top columns 40. In an exemplary embodiment, the column holder assembly 70 is operatively connected to a spindle support plate 72 for supporting the ring member 128. In an exemplary embodiment not shown, the column holder assembly 70 moves on a track secured to, or that are a part of, the top columns 40.

Continuing with FIG. 4, a first drive motor 84 is provided for causing rotational motion of the upper die spindle 135 upon which the upper die member 130 is operatively connected. The first drive motor 84 is preferably electrically powered but may also be powered by other means, such as by combustion. Because the upper die member 130 and the lower die member 120 are interconnected thru two or more positioning studs 122 which are carried by the upper die member 130 or other connecting techniques, during operation of the machine 100 both die members 120,130 are driven into rotation by the first drive motor 84. The disk blank 10 is therefore also driven into rotational motion about the Ay machine axis by this arrangement. The first drive motor 84 is operatively connected to the upper die spindle 135 via a motor support 118 such that its output shaft 82 is rotatable about the machine Ay axis.

As shown in FIG. 4, the first drive motor 84 is enclosed on at least two sides by cylinder rod supports 116 which are operatively connected by a cylinder rod adapter 114 for supporting forces from an upper lifting mechanism 94. The upper lifting mechanism 94 can adjust the vertical height of the upper die member 130 with an upper lifting mechanism output shaft 96. In an exemplary embodiment, the cylinder rod supports 116 may also be an enclosure formed from a single piece of material that the cylinder rod adapter 114 may be connected thereto. The lifting mechanism 94 is positioned along the vertical Ay axis. The upper lifting mechanism output shaft 96 is positioned along the vertical Ay axis and operatively connected to the cylinder rod adapter 114. In an exemplary embodiment not shown, the upper lifting mechanism 94 may be positioned away from the vertical Ay axis and therefore so may the output shaft 96. The lifting mechanism output shaft 96 may be continuously connected to the cylinder rod adapter 114 or can be disengaged during use or after use of the machine 100. The drive motor output shaft 82 is operatively connected to the upper die spindle 135 via a coupling hub 80 comprising suitable coupling devices.

Continuing with FIG. 4, mounted axially within the lower die member 120 is a splitting-swaging tool 155 which is operatively connected to a rotatable, vertically and laterally-movable, internal tool spindle 150. The spindle 150 is operatively connected to a ring member or tool spindle housing 156 via bearings 45 that allow the spindle 150 to be rotatable about the machine Ay axis when at the starting position and continuously rotatable during operation of the machine during lateral movement of the spindle 150 from the machine Ay axis to the parallel Ayc axis (as showin in FIG. 2). The tool spindle housing 156 is operatively connected to the bottom columns 30 via column holder assemblies 70 analogous to the column holder assemblies 70 in slideable engagement with the top columns 40. The column holder assemblies 70 are in slidable engagement with the bottom columns 30 and are operatively connected to spindle assembly plate adapters 74 and lateral spindle slides 76 which allow for lateral/horizontal movement of the internal tool spindle 150.

The internal tool spindle 150, along with the splitting-swaging tool 155, are moveable from the machine Ay axis to a parallel Ayc axis by a lateral motion inducing mechanism, such as an electric cylinder, hydraulic cylinder, pneumatic cylinder, or any other suitable powered mechanism that can induce lateral motion, and such mechanism is generally indicated at reference numeral 98. In an exemplary embodiment, the lateral motion inducing mechanism 98 is located on the side of the machine but it can be placed anywhere on or near the machine, including the front, back, top, or bottom. The motion of the splitting-swaging tool 155 from the Ay axis to the Ayc axis affects splitting and swaging of the disk blank center axial bore 12 as illustrated in FIGS. 1B and 1C.

Referring to FIG. 5 of the drawings, an enlarged view showing an embodiment of the machine mechanism which affects splitting and swaging of the disk blank center axial bore 12 is illustrated. In the figure, a disk blank 10 is firmly clamped between a lower die member 120 and an upper die member 130 which are both conically shaped but in other embodiments may be annularly-shaped. In this embodiment, the lower die member 120 has at least a pair of positioning stud bolts 122 which are threaded into bores 124 and which pass through the positioning bores 14 in the disk blank 10 and advance into matching bores 132 in the upper die member 130. In this way, the disk blank 10 is securely maintained for rotational motion about the machine Ay axis and within the horizontal plane of the Bx axis. The bottom die member 120 is carried by lower die spindle 125 which is connected to the first drive motor output shaft 82 as shown in FIG. 3. Accordingly, rotational motion of the upper die member 130 is achieved through the interconnection with the lower die member 120.

The splitting-swaging tool 155 is characterized by a splitting edge 152, a lower swaging surface 144 a, and an upper swaging surface 144 b. The swaging surfaces 144 a,144 b affect formation of bearing retaining flanges 20 as shown in FIG. 1C of the drawings. The splitting-swaging tool 155 is further characterized by a tapered flange portion 156 and an upper stud portion 158. The tapered flange portion 156 has at least one pair of mounting bores 160 into which bolts 162 may pass for engagement with threaded bores 164 in the internal tool spindle 150. The spindle 150 has a bore 154 into which the stud extension 158 of the splitting-swaging tool 155 is seated and maintained on the machine Ay axis during start-up of a machine operation. In an embodiment not shown, the splitting-swaging tool 155 may be mounted to the spindle 150 without an upper stud extension 158 via mounting bores 160 into which bolts 162 may pass for engagement with threaded bores 164 in the spindle 150. In such an embodiment, the internal tool spindle 150 may operate with or without a bore 154 as described in the previous embodiment. Continuing with FIG. 5, the spindle 150 may be further characterized by an annular flange 157 which carries inner bearing races 182 of bearings indicated generally at reference numeral 180. The outer bearing races 184 are mounted within a bore 192 in the tool spindle housing 156. In another embodiment not shown, the bearings 180 orientations do not require the spindle 150 to have an annular flange 157 for carrying inner bearing races 182.

It will, of course, be recognized that the metal splitting and swaging operation as described may require lubrication and/or cooling of the tools 40,41 and 44,155 while the disk blank 10 is being worked. Lubrication is accomplished by way of spray nozzles 250 which direct a suitable pressurized lubricant 252 into the working areas of tools 40 and 41 which are located outside of the die members 120 and 130 (as shown in FIG. 3). The splitting and swaging tool 155 receives lubricant 252 through a supply pathway indicated at 256 which is within the confines of the machine itself. The lubricant 252 flows downwardly into the chamber formed by the upper die member 130 where spinning action distributes it to the working area of the tool 155. Of course, various type vanes 258 may be configured into the inside surface of the die member 130 to facilitate distribution of the lubricant 252 where it is needed most. The lubricant 252 continues flowing downwardly through the disk blank center axial bore 12 and into the chamber formed by the lower die member 120 as illustrated in the drawing. When the lubricant reaches a particular level within the lower die member 120, it may be drawn off through one or more ports 260. The ports 260 may be closed by a plug 262 such that lubricant is retained in the chamber and thus available at startup of a machine operation when the supply through the pathway 256 is turned off.

Referring to FIG. 6, an alternative configuration for positioning and mounting of a disk blank 10 is illustrated in a partial elevational view in the area of the disk blank as it is clamped between two die members 120 and 130. This configuration is an alternative to the one illustrated in FIGS. 3, 4, and 5 comprising at least two positioning studs or bolts 122,162.

Referring to FIG. 6, for positioning and mounting of a disk blank 10 between the upper and lower die members 120,130 there is provided at least one of the upper die member 130 and the lower die member 120 is configured with a gripping portion 17 a. In an exemplary embodiment, the gripping portion 17 a is at least one annular raised ring of sharp edges or serrations on the die member surface for engagement with the disk blank 10. In another exemplary embodiment, the at least one of the upper die member 130 and lower die member 120 comprises concentric annular raised rings of sharp edges or serrations on the die member surface for engagement with the disk blank 10. The sharp edges or serrations may be of various shapes and set at various angles from an axis perpendicular to the surface of the die member. In one exemplary embodiment, the sharp edges or serrations may be symmetrical about a vertical axis through the tip of the sharp edge and perpendicular to the surface of the die member 120,130. In another embodiment, the sharp edges or serrations may be asymmetrical about a vertical axis through the tip of the sharp edge and perpendicular of the surface of the die member 120,130. In the asymmetrical embodiment, the sharp edge or serration may be biased towards either the center axial bore 12 or outer peripheral edge 16 of the disk blank 10. In a further exemplary embodiment, the raised sharp edges or serrations of the gripping portion 17 a are configured in a cross-like pattern that forms four quadrants in the surface of the die member. The cross-like pattern gripping portion 17 a can comprise multiple parallel lines of the raised sharp edges or serrations, or of a single line of the raised sharp edges or serrations. In any of the configurations disclosed above, when the lower die member 120 is raised into forceful engagement with the disk blank 10 and upper die member 130, sufficient frictional engagement exists between the die members 120,130 and the disk blank 10 such that it cannot move relatively with respect to either of them. This is so even when the machine splitting and swaging operations are in affect.

Referring back to FIG. 3, there is further provided a lateral motion inducing mechanism 98 for moving the splitting-swaging tool 155 horizontally for performing the splitting-swaging process of the disk blank 10. The lateral motion inducing mechanism 98 may comprise either an electrically-, mechanically-, or hydraulically-driven mechanism. In FIG. 3 the mechanism is generally indicated by reference numeral 98 and is mounted in association with the internal tool spindle 150, tool spindle housing 156, and the column holder assembly 70. As shown by way of example in the FIG. 3, when the lateral motion inducing mechanism 98 is initiated, the mechanism 98 applies pressure to the spindle housing 156. In the case of the mechanism 98 being a hydraulic cylinder, the hydraulic cylinder piston rod applies pressure to the spindle housing 156. As shown in FIG. 3, the spindle housing 156, internal tool spindle 150, and splitting-swaging tool 155 are moved to the left from the machine Ay axis. As a result, the splitting-swaging tool 155 makes contact with the center axial bore 12 of the disk blank 10. Of course, movement of the splitting-swaging tool 155 off of the machine Ay axis to the Ayc axis will affect reshaping of the disk blank center axial bore 12. The distance the lateral motion inducing mechanism 98 moves the internal tool spindle 150 and tool 155 can be altered by the user to adjust the shape of the resulting pulley.

Referring again to FIGS. 2-5 of the drawings, the following is a description of the machine operations. In the figures, specifically FIG. 3, a controller is indicated at reference numeral 200 and it is shown schematically as including various outputs “A-G” which may be used to control various functions of the machine 100. Firstly and assuming that the machine 100 is in the rest condition and the lower die member 120 is in a lowered position, a disk blank 10 is inserted onto the lower die member 120 which may be either in a lowered or slightly raised position depending on user preference. In the embodiments of FIGS. 3-4, the disk blank 10 is registered on the machine Ay axis via positioning bores 14 and mounting studs 122 on the lower die member 120. Of course, the alternative disk blank centering means illustrated and described with reference to FIG. 6 may be applied to accomplish the result.

To begin operations, the controller 200 sends a signal “A” to the lifting mechanism 90 to start raising the lower die member 120 such that forceful engagement and clamping action of the disk blank 10 between the lower die member 120 and the upper die member 130 is achieved. When the force is at least 10K pounds, a signal “B” is sent to the first drive motor 84 to affect rotation of the lower die member 120, disk blank 10, and upper die member 130. When the rotational speed of the disk blank 10 is at least 800 rpm, the controller 200 sends a signal “C” to the splitting tool 43 mechanism such as to affect engagement of the tool with the outer peripheral edge 16 of the disk blank 10. At about the same time, the controller 200 sends a signal “D” to the swaging tool 41 such that its mechanism moves the tool 41 to engage the split peripheral edge and affect swaging to a pulley groove 18. At either a predetermined instant in time later or at about the same time as signals C and D, the controller 200 sends a signal “E” to the lateral motion inducing mechanism 98 which affects lateral movement of the splitting-swaging tool 155 off of the machine Ay axis to a parallel Ayc axis (shown in FIG. 2) and to the lifting mechanism 94 to start lowering the splitting-swaging tool 155. This signal also initiates the second drive motor 88 operatively connected to the internal tool spindle 150 to begin rotation of the spindle 150 and splitting-swaging tool 155 about the Ay axis. The signal to begin rotation of the spindle 155 can alternatively be initiated at the times of signals B, C, and D so as to speed up the process and eliminate steps. The lateral movement of the tool 155 causes a contact with the disk blank center axial bore 12, splitting of the bore, and swaging to a retainer flange 20 configuration. When the tools 40,41,155 have reached their predetermined limits of motion into the disk blank peripheral edge 16 and center axial bore 12, the controller 200 sends signal “F” reversing tool movement such that they return to their initial machine positions. The first drive motor 84 and second drive motor 88 are shut down to halt rotational motion of the die means and the splitting-swaging tool 155 and a signal “F” is sent to reverse function of the lower lifting mechanism 90 such as to move the lower die member 120 to the lowered initial machine position and to reverse lifting mechanism 94 to raise the splitting-swaging tool 155. As described earlier with respect to machine lubrication, a signal “G” (FIG. 5) is sent from the controller 200 to close the valves 254 which supply lubricant 252 to the various tool operations. The finished product is removed from the machine and a new disk blank is inserted for the next machine operation.

While principles and modes of operation have been explained and illustrated with regard to particular embodiments, it must be understood, however, that this may be practiced otherwise than as specifically explained and illustrated without departing from its spirit or scope. 

1. An apparatus having primary Ay vertical and Bx horizontal axes to spinform a flat disk blank having a center axial bore into a pulley configuration exhibiting an outer peripheral pulley groove and bore flanges to contain a bearing, the machine comprising: a first spindle rotatable about the Ay axis; at least one die member operable to engage the disk blank and the first spindle causing the disk blank to rotate with the first spindle; a first motor coupled with the first spindle that is operable to cause the first spindle to rotate; a second spindle rotatable about the Ay axis and movable about the Bx horizontal axis causing the second spindle to rotate about an axis that is parallel to the Ay axis; a second motor coupled with the second spindle that is operable to cause the second spindle to rotate; a splitting-swaging tool coupled with the second spindle that rotates with the second spindle; and a controller coupled with the first motor and the second motor and operable to control the rotational speed of the first motor and second motor; wherein the controller is operable to control the first motor and the second motor to cause the splitting-swaging tool and the disk blank to rotate about the Ay axis in the same direction.
 2. The apparatus set forth in claim 1, wherein the controller is operable to cause the first and second motors to rotate at rotational speeds which causes rotational speed of the splitting-swaging tool to match the rotational speed of the disk blank.
 3. The apparatus set forth in claim 1, wherein the controller is operable to cause the first and second motors to rotate at rotational speeds that cause the rotational speeds of the splitting-swaging tool and the disk blank to be within 5% of each other.
 4. The apparatus set forth in claim 1, wherein the controller is operable to cause the first and second motors to rotate at rotational speeds that cause the rotational speeds of the splitting-swaging tool and the disk blank to be within 2% of each other.
 5. The apparatus set forth in claim 1, further comprising a splitting tool rotatably powered and movable on the Bx horizontal axis to engage the outer peripheral edge and affect spitting of the edge.
 6. The apparatus set forth in claim 1, further comprising a swaging tool rotatably powered and movable on the Bx horizontal axis to engage the outer peripheral edge and affect swaging of the edge into a pulley groove configuration.
 7. The apparatus set forth in claim 1, further comprising a lateral motion inducing mechanism for moving the second spindle horizontally causing the splitting-swaging tool to engage the center axial bore of the disk blank.
 8. The machine as claimed in claim 7, wherein the lateral motion inducing mechanism for moving the second spindle horizontally is a hydraulic cylinder, wherein the piston of the hydraulic cylinder is operatively coupled with the second spindle and affects horizontal movement of the second spindle and splitting-swaging tool.
 9. The machine as claimed in claim 7, wherein the lateral motion inducing mechanism for moving the second spindle horizontally is a pneumatic cylinder, wherein the piston of the pneumatic cylinder is operatively coupled with the second spindle and affects horizontal movement of the second spindle and the splitting-swaging tool.
 10. The apparatus set forth in claim 1, further comprising a spur-ring gear combination coupling the first motor to the first spindle.
 11. The apparatus set forth in claim 1, the at least one die member comprises an upper die member and a lower die member, wherein the disk blank is mounted between the upper die member and the lower die member.
 12. The apparatus set forth in claim 11, wherein the upper die member has a bore allowing the splitting-swaging tool to pass therethrough to engage the disk blank.
 13. The apparatus set forth in claim 12, wherein the upper die member is conical in shape.
 14. The apparatus set forth in claim 12, further comprising a lifting mechanism that the height of the second spindle along the Ay axis.
 15. The apparatus set forth in claim 14, wherein the lifting mechanism comprises a hydraulically operated piston that is controlled by the controller. 